CN101726413A - Method of fault diagnosis on ball socketed bearing of steel-making converter by comprehensive analysis - Google Patents
Method of fault diagnosis on ball socketed bearing of steel-making converter by comprehensive analysis Download PDFInfo
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- CN101726413A CN101726413A CN200910243648A CN200910243648A CN101726413A CN 101726413 A CN101726413 A CN 101726413A CN 200910243648 A CN200910243648 A CN 200910243648A CN 200910243648 A CN200910243648 A CN 200910243648A CN 101726413 A CN101726413 A CN 101726413A
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Abstract
The invention discloses a method of fault diagnosis on a ball socketed bearing of a steel-making converter by comprehensive analysis. The method carries out fault diagnosis on the ball socketed bearing of the steel-making converter by using vibration signal analysis and grease oil analysis. The method comprises the following steps of: firstly, selecting evenly distributed measuring points on the periphery of the outer ring of the bearing, and then punching bearing seats at the measuring points; carrying out resonance demodulation and wavelet noise reduction analysis on acquired bearing vibration signals; firstly, selecting centre frequency and bandwidth according to frequency bands generated in resonance peaks in a frequency spectrogram to carry out bandpass filtering, and then carrying out wavelet noise reduction and Hilbert demodulation treatment on the filtered signals; on the basis of detecting the conventional typical properties, carrying out qualitative and quantitative analysis on the components and the content of metal wearers in oil samples by using spectrum analysis and ferrographic analysis, and judging according to the detection result; and comparing and synthesizing two analysis results to make a fault diagnosis report. The invention can effectively increase the accuracy of fault diagnosis, thereby being beneficial to discovering fault hidden troubles as early as possible and avoiding major accidents happening.
Description
Technical field
The present invention relates to a kind of method for diagnosing faults of bearing, particularly a kind of integrated use analysis of vibration signal and fluid (fat) are analyzed the method for the steelmaking converter ball socketed bearing being carried out fault diagnosis.
Background technology
As the steelmaking converter of large-sized low-speed heave-load device is key equipment in the modern steel enterprise production process.The principal feature of this kind equipment is that working speed is low, and bearing load is big.Because low-speed running, load is complicated and changeable, and the equipment long-play adds that production environment is abominable, the reason of insufficient lubrication, and equipment breaks down easily.In case this kind equipment catastrophic failure will cause the interruption of production, when serious even cause casualties, and the complicacy of device structure makes and repairs very difficultly, and maintenance cost is very high, causes enormous economic loss and harmful effect to enterprise.As the bearing of the critical component in the supporting mechanism, be the parts that the most easily break down in the steelmaking converter.Therefore, bearing is the emphasis monitoring target in producing always, and it is carried out status monitoring and fault diagnosis is of great practical significance.
At present, the most extensive with the bearing vibration signal analysis in Application in Fault Diagnosis.But the faint property of the early stage vibration signal of equipment failure, production scene very noisy have brought very big difficulty to the interference of bearing fault vibration signal to carrying out successfully fault diagnosis by this method.Utilization fluid (fat) analytical technology can be obtained the lubricated and faulted condition of equipment, determines the position and the type of device fails.But compare the real-time collection and the analysis of vibration signal, there is limitation in the method that adopts regular extraction fluid (fat) to analyze aspect the timely discovering device fault.Therefore, the divided oscillation signal analysis method that application resonance and demodulation and wavelet de-noising combine carries out feature extraction to the Weak fault signal, and the analysis of itself and fluid (fat) is carried out comprehensive, and can overcome the deficiency that single method carries out fault diagnosis effectively, improve accurate rate of diagnosis.
Summary of the invention
The objective of the invention is to, by a kind of method of the steelmaking converter ball socketed bearing being carried out fault diagnosis is provided, in time find the potential faults of steelmaking converter ball socketed bearing, improve accuracy of fault diagnosis, for iron and steel enterprise provides effective maintenance suggestion, the fault diagnosis of carrying out success for the steelmaking converter ball socketed bearing provides important theoretical foundation and implementation method.
For achieving the above object, this method adopts technical scheme as follows:
A kind of integrated use analysis of vibration signal and fluid (fat) are analyzed the method for the steelmaking converter ball socketed bearing being carried out fault diagnosis, comprise the steps:
1) fixed form of the mounting means of the selection of measuring point, sensor and sensor on the bearing:
The selection of measuring point adopt on the bearing outer ring circumference, evenly distribute four respectively with the measuring point at surface level and vertical plane inclination angle at 45.The mounting means of sensor is by punching on bearing seat, at the point position that chooses bearing seat is punched according to the bigger size of ratio sensor shape, the acceleration transducer base directly being contacted with bearing outer ring.The fixed form of sensor adopts the high strength magnet base to fix.
2) analysis of vibration signal:
According to step 1 sensor installation, the bearing vibration signal that degree of will speed up sensor collects in real time carries out being uploaded in the computing machine after anti-aliasing filtering, amplification and the A/D conversion to data acquisition unit through cable transmission, and signal is carried out resonance and demodulation and wavelet de-noising analysis.At first do spectrum analysis, carry out bandpass filtering according to Frequency Band Selection centre frequency and bandwidth that resonance peak among the signal spectrum figure occurs.Filtered signal is carried out wavelet de-noising to be handled.Concrete steps are: select a wavelet basis earlier and decompose the number of plies, signal is carried out wavelet decomposition; Determine threshold function table, the threshold value of selecting the passing threshold rule to obtain quantizes the high frequency coefficient that decomposition obtains; According to the lowermost layer low-frequency approximation signal after quantizing and each floor height frequency detail signal, make wavelet reconstruction.At last, to carrying out the Hilbert demodulation analysis through the signal after resonant belt pass filter and the wavelet de-noising processing.Find out the outstanding frequency content of low-frequency range, judge whether these frequency contents exist the relation of fundamental frequency and frequency multiplication.If exist, be judged as potential faults.According to fundamental component, contrast the bearing fault characteristic frequency that calculates according to theoretical and formula again, the position that failure judgement takes place.
3) fluid (fat) is analyzed:
Regularly extract the oil sample in the steelmaking converter ball socketed bearing.On the basis of detecting the conventional physical and chemical index of fluid (fat), application of spectral, analyzing iron spectrum technology are carried out qualitative and quantitative analysis to the composition and the content of galling thing in the oil sample.Make judgement according to testing result: have the content of arbitrary composition to surpass setting value in the galling thing in the oil sample, be judged as potential faults; The content of none composition surpasses setting value in the galling thing in the oil sample, is judged as non-fault hidden danger.
4) analysis-by-synthesis:
Judging that by step 2 bearing exists on the basis of potential faults, carry out step 3 immediately and draw analysis result.Comprehensive relatively two kinds of analysis results if judge that all bearing breaks down, then write out fault diagnosis report, the maintenance of suggestion manufacturer; If fluid (fat) analysis and judgement bearing is non-fault hidden danger still, then pay close attention to the running status of steelmaking converter ball socketed bearing in the recent period, and carry out analysis-by-synthesis once more.
By bearing seat is punched sensor is directly contacted with bearing outer ring, reduced the transmission interface of this vibration signal of bearing seat, reduced the decay of signal effectively.
The steelmaking converter ball socketed bearing is carried out analysis of vibration signal, the method that adopts resonance and demodulation and wavelet de-noising to combine, twice pair of signal that is flooded by the on-the-spot very noisy of commercial production carries out noise reduction process, can improve signal to noise ratio (S/N ratio) effectively.Simultaneously, owing to be to gather in real time and analyze, help finding initial failure.
The steelmaking converter ball socketed bearing is carried out fluid (fat) analysis, can obtain the result who matches with the actual motion state.
The method that integrated use analysis of vibration signal and fluid (fat) are analyzed can overcome the limitation that occurs mistaken diagnosis when single method carries out fault diagnosis, can improve accurate rate of diagnosis effectively.Simultaneously, use this integrated approach, help carrying out the initial failure diagnosis, realize the precognition maintenance.
Compared with prior art, beneficial effect of the present invention is:
1) punching makes sensor base directly contact with bearing outer ring on bearing seat, compare with the existing mode that sensor is installed on bearing seat, reduce the decay when bearing vibration signal is passed through this transmission interface of bearing seat, can obtain the vibration signal of more approaching reflection bearing running status.
2) the divided oscillation signal analysis method of employing resonance and demodulation and wavelet de-noising, carry out noise reduction process by bandpass filtering and twice pair of vibration signal of high frequency coefficient threshold process priority, improve signal to noise ratio (S/N ratio) effectively, helped the extraction of the Weak fault signal characteristic that flooded by powerful industry spot noise.
3) analysis of vibration signal and the analysis integrated running status to the steelmaking converter ball socketed bearing of fluid (fat) are judged, can effectively be improved accuracy of fault diagnosis, be convenient to find as early as possible potential faults, avoid the generation of major accident.
Description of drawings
Fig. 1 is an overview flow chart of the present invention;
Fig. 2 is the analysis of vibration signal process flow diagram;
Fig. 3 is the synoptic diagram of steelmaking converter furnace binding;
Fig. 4 is the scheme of installation of sensor;
Fig. 5 is fluid (fat) analysis process figure.
Embodiment
The present invention is described in detail below in conjunction with accompanying drawing.
As shown in Figure 1, a kind of integrated use analysis of vibration signal and fluid (fat) analysis to the flow process that the steelmaking converter ball socketed bearing carries out the method for fault diagnosis are: respectively the steelmaking converter ball socketed bearing is carried out analysis of vibration signal and fluid (fat) analysis, comprehensively both results carry out final fault diagnosis then.
As shown in Figure 2, analysis of vibration signal mainly contains three steps:
1) installation of the selection of measuring point, sensor and fixing.Fig. 3 is the furnace binding figure of steelmaking converter.Number in the figure 4 is ball socketed bearing and bearing seat.Because the gudgeon rotating speed is low, carrying is big, so ball socketed bearing is that fault is easily sent out the position, becomes the emphasis parts of monitoring.As shown in Figure 4, wherein, 10 is acceleration sensor, and 11 are the bearing seat perforation, and 12 is the bearing outer ring circumference, and 13 is bearing seat; At first on the bearing outer ring circumference, select four respectively with the equally distributed measuring point at surface level and vertical plane inclination angle at 45, at the measuring point place bearing seat is punched then, punch according to the size that the ratio sensor shape is bigger, sensor base is directly contacted with bearing outer ring.With the high strength magnetic support sensor is fixed at last.
2) vibration signal with sensor acquisition imports in several institutes collector by cable one end interface, carries out anti-aliasing filtering, amplification and A/D and walks around and change.Signal after handling is imported to the analysis of carrying out vibration signal in the computing machine.
3) signal is carried out spectrum analysis, judge whether there is the resonance spectrum peak in the spectrogram.Then do not judge that tentatively bearing does not occur unusually, carries out real-time vibration signals collecting once more.Otherwise the Frequency point with resonance peak amplitude maximum is a centre frequency, and the bearing inner race fault characteristic frequency sideband frequency range of frequency tripling at least is that bandwidth is carried out bandpass filtering.Choose the most frequently used db wavelet basis, sym wavelet basis and the coif wavelet basis signal after to bandpass filtering and distinguish three to five layers of decomposition, the high frequency detail signal of selecting for use hard-threshold, soft-threshold and three kinds of threshold function tables of compromise threshold value and heursure threshold value that decomposition is obtained carries out threshold value quantizing to be handled, and carries out wavelet reconstruction then.Owing to have the different choice of wavelet basis, the decomposition number of plies, threshold function table and threshold value, can obtain the result of 27 kinds of wavelet de-noisings so altogether.For selecting the best result of noise reduction, be criterion with the signal to noise ratio (S/N ratio), one group that gets the signal to noise ratio (S/N ratio) maximum as final noise reduction result.The computing formula of signal to noise ratio (S/N ratio) is as follows:
In the formula, x (n) is the signal through bandpass filtering,
Be the signal behind wavelet de-noising, N is a sampling number.
Signal behind the noise reduction is made the Hilbert demodulation analysis, judged whether that tangible fundamental frequency and frequency multiplication composition exist.Do not exist and then continue to gather vibration signal in real time and analyze according to above-mentioned flow process once more.Exist and judge tentatively that then bearing breaks down.Each fault characteristic frequency of fundamental frequency and bearing is compared.When a certain fault characteristic frequency of fundamental frequency and bearing near the time, the further position that takes place of failure judgement.
As shown in Figure 5, fluid (fat) analysis mainly contains three steps:
1) oil-out with the steelmaking converter ball socketed bearing is the fluid sampling spot, uses professional sampling instrument stripping oil liquid.The time interval of sampling is adjusted according to the virtual condition of equipment operation.Be in break in period at equipment, shorten the sample interval when analysis of vibration signal is found potential faults and equipment near the maintenance interval; At the equipment normal operation period, the sample period can be prolonged.Based on the operation characteristics of steelmaking converter, determine that the fluid extracting cycle the run time that equipment being normal is two months.
2) oil sample that extracts being carried out conventional physical and chemical index detects.Choose viscosity, moisture, impurity particle, acid number, oxidation and flash-point as analysis indexes, judge the deterioration metamorphic grade of fluid (fat).Testing result and setting value are compared.When the result surpasses setting value, judge that fluid (fat) greasy property descends, and proceeds spectrum and analyzing iron spectrum; Otherwise greasy property is good, extracts oil sample once more according to the sample period.
3) application of spectral, analyzing iron spectrum technology are carried out qualitative and detection by quantitative to the oil sample that detects through conventional physical and chemical index.Composition and content and setting value comparison with the galling thing in the detected oil sample.The content of none composition surpasses setting value in the galling thing in the oil sample, is judged as non-fault hidden danger, extracts oil sample once more according to the sample period; In the galling thing in the oil sample, there is the content of arbitrary composition to surpass setting value, is judged to be and has potential faults.
As shown in Figure 1, the integrated use of analysis of vibration signal and fluid (fat) analysis mainly contains two steps:
1) uses analysis of vibration signal and judge when there is not potential faults in bearing as yet, gather vibration signal once more in real time, and carry out fluid shown in Figure 5 (fat) analysis process.
2) use analysis of vibration signal and judge when there is potential faults in bearing, shorten set fluid (fat) sample period, carry out fluid shown in Figure 5 (fat) analytical procedure immediately and obtain analysis result.Two kinds of analysis results are compared and comprehensive,, then in the recent period the running status of steelmaking converter ball socketed bearing is monitored closely if the conclusion that fluid (fat) analysis obtains is a non-fault hidden danger, and analysis-by-synthesis once more.If conclusion is bearing and has potential faults, determine that then fault has taken place the steelmaking converter ball socketed bearing, write out fault diagnosis report, and propose the suggestion of maintenance to manufacturer.
Claims (4)
1. one kind is carried out the method for fault diagnosis by analysis-by-synthesis to the steelmaking converter ball socketed bearing, and applying vibration signal analysis and the analysis of grease liquid are carried out fault diagnosis to the steelmaking converter ball socketed bearing, it is characterized in that, may further comprise the steps:
At first on the bearing outer ring circumference, select several to become the equally distributed measuring point at inclination angle respectively with vertical plane with surface level, at the measuring point place bearing seat is punched then, punch according to the size that the ratio sensor shape is bigger, sensor base is directly contacted with bearing outer ring, adopt high strength magnetic support fixation of sensor;
Described analysis of vibration signal comprises: the bearing vibration signal that degree of will speed up sensor collects in real time carries out being uploaded in the computing machine after anti-aliasing filtering, amplification and the A/D conversion to data acquisition unit through cable transmission, and signal is carried out resonance and demodulation and wavelet de-noising analysis; At first do spectrum analysis, carry out bandpass filtering, filtered signal is carried out wavelet de-noising handle according to Frequency Band Selection centre frequency and bandwidth that resonance peak among the signal spectrum figure occurs; Concrete steps are:
A, wavelet basis of selection and the decomposition number of plies are carried out wavelet decomposition to signal;
B, determine threshold function table, the threshold value of selecting the passing threshold rule to obtain quantizes the high frequency coefficient that decomposition obtains;
Lowermost layer low-frequency approximation signal after c, the change and each floor height be detail signal frequently, makes wavelet reconstruction;
D finds out the outstanding frequency content of low-frequency range to carrying out the Hilbert demodulation analysis through the signal after resonant belt pass filter and the wavelet de-noising processing, judges whether these frequency contents exist the relation of fundamental frequency and frequency multiplication; If exist, be judged as potential faults; According to fundamental component, contrast the bearing fault characteristic frequency that calculates according to theoretical and formula again, the position that failure judgement takes place;
The analysis of described grease liquid comprises:
Regularly extract the oil sample in the steelmaking converter ball socketed bearing;
On the basis of detecting the conventional physical and chemical index of grease liquid, application of spectral, analyzing iron spectrum carry out qualitative and quantitative analysis to the composition and the content of galling thing in the oil sample, make judgement according to testing result: have the content of arbitrary composition to surpass setting value in the galling thing in the oil sample, be judged as potential faults; The content of none composition surpasses setting value in the galling thing in the oil sample, is judged as non-fault hidden danger;
When judging that by analysis of vibration signal there is potential faults in bearing, carry out the analysis of grease liquid and obtain analysis result; Two kinds of analysis results are compared with comprehensive, have potential faults, determine that then bearing breaks down, write out fault diagnosis report if all be judged as; If the conclusion that the analysis of grease liquid obtains is a non-fault hidden danger, then in the recent period the running status of steelmaking converter ball socketed bearing is monitored closely, and analysis-by-synthesis once more.
2. according to claim 1ly by analysis-by-synthesis the steelmaking converter ball socketed bearing is carried out the method for fault diagnosis, it is characterized in that: the equally distributed measuring point at described inclination angle is four.
3. according to claim 1ly by analysis-by-synthesis the steelmaking converter ball socketed bearing is carried out the method for fault diagnosis, it is characterized in that: the angle at described inclination angle is 45 °.
4. according to claim 1ly the steelmaking converter ball socketed bearing is carried out the method for fault diagnosis, it is characterized in that the conventional physical and chemical index of described grease liquid comprises: viscosity, moisture, impurity particle, acid number, oxidation and flash-point by analysis-by-synthesis.
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